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User Guide

Liquid cooled heavy duty inductance

unit

EC-LTS1200-410

danfoss.com

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1. General information

1.1. Copyright .........................................................................................................................................................................................

1.2. Intended use of the user guide ...............................................................................................................................................

1.3. Product naming convention ....................................................................................................................................................

1.4. Conformity according to standards .......................................................................................................................................

1.5. Warranty ..........................................................................................................................................................................................

1.6. Terms and abbreviations ...........................................................................................................................................................

1.7. Trademarks .....................................................................................................................................................................................

1.8. Responsibility of the manufacturer .......................................................................................................................................

2. Safety information

2.1. General safety statement ..........................................................................................................................................................

2.2. Safety message signal words ...................................................................................................................................................

2.3. Safety symbols ..............................................................................................................................................................................

2.4. Personal protective equipment ..............................................................................................................................................

2.5. Electromagnetic compatibility (EMC) ...................................................................................................................................

2.6. Installation safety .........................................................................................................................................................................

2.7. Operation safety .........................................................................................................................................................................

3. Product overview

3.1. Intended use of the electric device .....................................................................................................................................

3.2. System introduction .................................................................................................................................................................

3.3. Cooling ..........................................................................................................................................................................................

3.4. Rating plate ..................................................................................................................................................................................

3.5. Tightening torques ....................................................................................................................................................................

4. Transportation and storage

4.1. Transportation ............................................................................................................................................................................

4.2. Receiving and unpacking .......................................................................................................................................................

4.3. Lifting .............................................................................................................................................................................................

4.4. Handling ........................................................................................................................................................................................

4.5. Storage ...........................................................................................................................................................................................

5. Installation

5.1. Required tools .............................................................................................................................................................................

5.2. Mechanical installation ............................................................................................................................................................

5.2.1. Allowed mounting position ...........................................................................................................................................

5.2.2. Installation procedure ......................................................................................................................................................

5.2.3. Cooling connections ........................................................................................................................................................

5.2.4. Recommended coolants .................................................................................................................................................

5.3. Electrical installation .................................................................................................................................................................

5.3.1. Grounding ............................................................................................................................................................................

5.3.2. Cable gland assembly and power line connection ...............................................................................................

5.3.3. Cabling and wiring ............................................................................................................................................................

5.3.4. High voltage connections ..............................................................................................................................................

5.3.5. Low voltage connections ................................................................................................................................................

6. Operation

6.1. Operation conditions ...............................................................................................................................................................

6.2. Condition monitoring during operation ...........................................................................................................................

7. Maintenance

EC-LTS1200-410

Table of Contents

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7.1. Cooling system maintenance ................................................................................................................................................

7.2. Regular maintenance ...............................................................................................................................................................

7.3. Cleaning ........................................................................................................................................................................................

8. Dismounting and disposal of the electric device

9. Troubleshooting

10. Aftersales

10.1. Service policy ............................................................................................................................................................................

10.2. Service parts ..............................................................................................................................................................................

EC-LTS1200-410

Table of Contents

2 | ©Danfoss | Produced By: Danfoss Power Solutions | September 2020 | BC355449988603en-000101

Revision Information

1

EC-LTS1200-410


Copyright

Danfoss Oy. All rights reserved.

No parts of this user guide may be reproduced or transmitted in any form or by any means,electrical or mechanical including photocopying, recording or by an information storage orretrieval system, without permission in writing from the publisher.

All speci�cations and contents of this user guide are subject to change without notice.

Intended use of the user guide

This user guide contains instructions necessary to safely and properly handle, install and maintainthe electric device. They should be brought to the attention of anyone who installs or maintainsthe electric device or associated equipment.

All of the safety warnings and instructions in this user guide must be followed to prevent injury topersonnel or damage to property. Only quali�ed and authorized personnel, familiar with healthand safety requirements and national legislation, shall be permitted to handle, install and maintainthe device.

This user guide must be kept for future reference during installation, operation and maintenance.

This user guide uses illustrations as examples only. Illustrations in this user guide may notnecessarily re�ect all system features.

Product naming convention

In this user guide the EC-LTS external inductance unit is referred to as the electric device.

The following naming convention is used to refer to electric device type code and options:

EC-LTS1200-XXX

Part of the name Explanation

EC Electric Converter

LTS1200 Type code part 1

XXX Type code part 2

Options are presented in the Table below. Standard options are indicated by a star (*).

Table 1. EC-LTS1200-400 options

Variant Code Description Additional information

Cable glands

* No cable glands No cable glands or plugs

+CG1M25/M32 cable

glands

3x M25 cable glands, 3x M32 cable glands and 2x M32

plugs in delivery

Marine

classi�cation

*No marine

classi�cation

+CL1 ABS American Bureau of Shipping

+CL2 BV Bureau Veritas

+CL3 DNV GL DNV GL AS

+CL4 LR Lloyd’s Register

+CL5 RINA

EC-LTS1200-410



Conformity according to standards

The electric device has been designed in accordance with the essential parts of the followingdirectives and to meet the requirements of the standards:

Table 2. Applicable directives

Directives Explanation

Low Voltage

Directive 2014/35/EU

Electrical equipment means any equipment designed for use with a voltage rating of

between 50 and 1000 V for alternating current.

Standards

IEC/EN 61800-5-1:

2007

Adjustable speed electrical power drive systems - Part 5-1: Safety reguirements -

Electrical, thermal and energy

Warranty

Danfoss offers warranty against defects in workmanship and materials for its products for a periodof twelve (12) months from commissioning or eighteen months (18) from delivery (Incoterms-EXW), whichever occurs �rst.

In order for the warranty to be valid, the customer must follow the requirements of this and allrelated documents, especially those set out in the product installation and maintenancedocuments, as well as the applicable standards and regulations in force in each country.

Defects arising from the improper or negligent use, operation, and/or installation of theequipment, non-execution of regular preventive maintenance, as well as defects resulting fromexternal factors or equipment and components not supplied/recommended by Danfoss, will notbe covered by the warranty.

The warranty will not apply if the customer at its own discretion makes repairs and/ormodi�cations to the equipment without prior written consent from Danfoss.

Terms and abbreviations

Following symbols, terms and abbreviations may exist in this user guide.

Term/ Abbreviation Explanation

AC Alternating current

DC Direct current

MCB Miniature circuit breaker

EMC Electromagnetic compatibility

EMI Electromagnetic interference

EC-LTS1200-410



Symbol Variable Unit

UDC DC link voltage V

Uac AC output voltage V

In Rated current Arms

Pn Rated power kW

fin/out Input / Output frequency Hz

fswitch Switching frequency kHz

Ipeak Overcurrent limit A

Tamb Rated ambient temperature °C

GND Ground in electrical connections

R Resistance Ω

Trademarks

All trademarks in this material are property of the respective companies. Danfoss and the Danfosslogotype are trademarks of Danfoss A/S. All rights reserved.

Responsibility of the manufacturer

Danfoss is responsible for the safety, reliability and performance of the electric device only if:

Handling, mounting, installation, operation and maintenance are carried out by quali�ed andauthorized service personnel.

The installation of the system complies with the requirements of the appropriate regulations.

The electric device is used in accordance with the instructions in this user guide.

The electric device is installed, maintained and serviced in accordance with the instructions inthis user guide.

EC-LTS1200-410



General safety statement

The electric device is intended for use as a component for industrial and commercial installations.The end product containing the electric device must conform with all related regulations.

The use of the electric device is prohibited in hazardous areas unless it is expressly designed forsuch use.

The electric device is intended for installation, use and maintenance by quali�ed personnel,familiar with health and safety requirements and national legislation. Ignoring these instructionsmay invalidate all applicable warranties.

These instructions must be followed to ensure safe and proper installation, operation andmaintenance of the electric device. They should be brought to the attention of anyone whoinstalls, operates or maintains the electric device or associated equipment.

High voltage and rotating parts can cause serious or fatal injuries. For the electric device coveredby this user guide, it is important to observe safety precautions to protect personnel from possibleinjury.

Safety message signal words

Safety message signal words indicate the severity of a potential hazard.

DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death orserious injury.

WARNING Indicates a potentially hazardous situation which, if not avoided, could result in deathor serious injury.

CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor ormoderate injury. CAUTION may also alert against unsafe practices.

NOTICE Indicates a potentially hazardous situation which, if not avoided, could result in propertydamage.

Safety symbols

The following safety and information related symbols may exist in this user guide and on theelectric device.

Danger

This symbol is is identi�ed by a yellow background, red octagonal band and a black STOP text. It indicates a

hazardous situation that causes severe injury or death. Action indicated by this symbol may not be executed.

General warning

This symbol is identi�ed by a yellow background, black triangular band, and a black exclamation point

symbol. It indicates a general potentially hazardous situation.

Electric shock warning

The symbol is identi�ed by a yellow background, black triangular band, and a black arrowhead symbol. It

indicates dangerous electric voltage that could cause an electric shock to a person.

Burn warning

The symbol is identi�ed by a yellow background, black triangular band, and a black wavy lines- symbol. It

indicates a hot device that could cause burns to a person.

The symbol also indicates that the device should be placed and installed so that contact with its potentially

hot surface is not possible.

Magnet warning

The symbol is identi�ed by a yellow background, black triangular band, and a black magnet symbol. It

indicates strong magnetic �eld that could cause harm to a person or property.

EC-LTS1200-410



Poison warning.

The symbol is identi�ed by a yellow background, black triangular band, and a skull and crossbones symbol. It

indicates a poisonous substance that could kill or cause an injury to a person.

Electric shock warning - Read the instructions in the user guide.

General Information.

Read the instructions in the user guide.

Personal protective equipment

Personal protective equipment shall be used when necessary during handling, installation andmaintenance of the electric device to avoid injury.

Use eye protective equipment like safety goggles or mask when working with the electric device. Permanent damage to

the eye could be caused if hot water, glycol or other �uids splash.

Use hearing protective equipment when working on the electric device in noisy environment! Hearing injuries could be

caused by too loud noise (noise in excess of 85 dBA).

Use head protective equipment like helmet when mounting or dismounting the electric device! Head injuries could be

caused by object impact.

Use cut resistant gloves when handling and maintaining the electric device! There is a risk of cut injuries.

Use protective footwear when lifting or moving the electric device! Foot injuries could be caused if lifting system or

lifting brackets fail.

EC-LTS1200-410



Electromagnetic compatibility (EMC)

When interfacing other equipment, connect only equipment that are speci�ed as part of the system and that

are compatible with each other.

Magnetic and electromagnetic �elds generated near current-carrying conductors and permanent magnets in electric

devices are a health danger to persons with heart pacemakers, metal implants and hearing aids. Persons with a heart

pacemaker, metal implants or hearing aids must consult a doctor before they enter the following areas:

Areas in which electric equipment and parts are operated.

Areas in which electric equipment with permanent magnets are stored, mounted, operated or repaired.

If necessary, do a special electromagnetic compatibility (EMC) test on the installation.

EMC stands for Electromagnetic compatibility. It is the ability of electric equipment to operatewithout problems within an electromagnetic environment. Likewise, the equipment must notdisturb or interfere with any other product or system within its locality. This is a legal requirementfor all equipment taken into service within the European Economic Area (EEA).

The products are designed with high standards of EMC in mind. Connect the power lines andgroundings by the instructions in this user guide to achieve the required level of EMC protection.

It is the responsibility of the installer to make sure that the equipment or system into which theproduct is incorporated complies with the EMC legislation of the country of use.

Installation safety

Only trained and quali�ed personnel familiar with the relevant safety requirements can install the electric device. If the

electric device is installed incorrectly it may lead to safety hazard.

Make sure of correct grounding connections. Do not run the electric device without correctly attached protective earth

conductor. The grounding cable must be sufficient to carry the maximum supply fault current which is normally limited

by the fuses or Miniature Circuit Breaker (MCB). Suitably rated fuses or MCB should be �tted in the mains supply of the

electric device, by the local legislation and recommendations.

Use only correct (type and value) protective fuses with the high voltage DC-system.

Do not do any work on the electric device control cables when the power is applied to the electric device or to the

external control circuits.

The control input functions of the electric device – for example stop/start must be secured using independent channel

protection in safety critical applications. All applications where malfunction could cause injury or loss of life must be

subject to a risk assessment and improve control signal protection if needed.

Do not activate the automatic fault reset function on any system, where this may cause a potentially dangerous

situation. Reason for every fault situation should be determined before resetting the fault.

Make sure that the supply voltage corresponds to the speci�cation of the electric device.

EC-LTS1200-410



Do not attempt to repair the electric device. In the case of suspected fault or malfunction, contact Danfoss or

Danfoss authorized service center for further assistance.

When you install the electric device, make sure that the cooling system and the used coolant meet the speci�cations of

the manufacturer. Make sure that the cooling system is in use when the DC-link is powered.

If the control cabling is installed close with the power cabling, make sure that minimum separation distance is 100 mm

and crossings are at 90 degrees. Make sure that all terminal connections are tightened correctly by the instructions.

Electric device must not be opened (excluding the connection box lid). Any attempt causes loss of warranty.

Within the European Union, all machinery in which this product is used must comply with Directive 98/37/EC, Safety of

Machinery. In particular, the machine manufacturer is responsible for providing a main switch and ensuring the electrical

equipment complies with EN60204-1.

Use correct personal protective equipment when you are near the electric device.

Read the instructions in this user guide before you start to install the electric device.

Operation safety

Do not use the electric device without correctly dimensioned and operating cooling system.

Maximum operation temperature must not be exceeded to avoid permanent damage to the electrical device.

The requirements of this user guide and other related instructions and standards must be followed

EC-LTS1200-410



Do not touch the electric device during operation. The surface of the electric device can be hot.

This electric device is intended for professional use as complete equipment or system and as part of a �xed installation.

The electric device uses high voltages and currents, and it has large amounts of stored electrical energy. Close attention

is required to system design and electrical installation to avoid hazards in either normal operation or in the event of

equipment malfunction.

The electric device can only be used in the applications it is intended for. The rated nominal values and operational

conditions are shown in the rating plate.

EC-LTS1200-410



The advantages and features of the electric device:

Extremely compact design – 410 A.

High enclosure class IP67 – sealed from moisture and dust.

Ambient temperature -40ºC...105ºC.

Robust design withstanding high levels of mechanical vibrations and shocks.

Designed especially for highly cyclical loads typical in heavy mobile work machines.

Figure 1. Main components

EC-LTS1200-410

3. Product overview


1 L1 connection

2 L2 connection

3 L3 connection

4 +LV connection plugged (con�gurable, see +CG option below)

5 Cooling inlet / outlet connections

6 X2 temperature measurement connector

7 +LV connection cable gland (con�gurable, see +CG option below)

8 X1 plugged, not in use

9 M8 Mounting points, 6 pcs on the sides and 8 pcs on the bottom

+CG1 option comes with a selection of cable glands and plugs. Typical cable gland con�gurationsare shown in the Table below.

Table 3. Typical cable gland con�gurations for option +CG1

Connections Typical cable gland applications

Connection to DC/DC-converter (L1, L2,

L3)3x M25 cable glands 3x M25 cable glands 3x M25 cable glands

Low voltage side positive connection

(+LV)

1x M32 cable gland, 2x M32

plugs

2x M32 cable glands, 1x M32

plugs

3x M32 cable glands, no

plugs

Intended use of the electric device

The electric device is intended only for professional use. Installation, operation and maintenance of the electric

device is permitted only for trained personnel and professionals.

The electric device is intended for �xed installation, as a part of complete power generation equipment or system.

Typical applications for the electric device are:

System component designed to be combined with EC-C1200-450 DCDC-converter, used totransfer energy between two different voltage levels.

Figure 2. Application example

EC-LTS1200-410

3. Product overview


EC-C1200 DC/DC converter combined with the EC-LTS unit. LV+ and LV- can be connected, forexample, to battery and DC+ and DC- to DC-link. EC-C1200 would then control the batterydischarging and charging.

Not allowed use of the electric device

It is forbidden to use, handle, maintain and storage the electric device in following ways (includingbut not limited to):

Using the electric device for other purposes than de�ned in the user guide.

Disregarding the obligation to comply with the user guide, safety signs and rating plate of theelectrical device.

Using the electric device, making adjustments and maintenance without �rst reading the userguide.

Exceeding the designed limits during the operation.

Using non-original service parts of wrong material causing corrosion problems and mechanicalfailures in time.

Operating and performing maintenance on the electric device without appropriate personalprotective equipment.

Using the electric device for supporting other structures or indirect movements.

Causing any kind of impact forces to the electric device (for example hitting or hammering ordropping objects).

Operating the electric device with electric connections other than de�ned in the user guide.

Operating the electric device with insufficiently tightened connections or cable glands.

Operating the electric device with power cables routed against the instructions.

Operating the electric device without properly dimensioned and operating cooling system.

Accessing the connection box(es) of the electric device, performing maintenance oradjustment operations without securing that the electricity is disconnected and electricdevice is discharged as de�ned in the user guide.

Lifting the electric device with additional load attached.

Using the electric device in potentially explosive environment.

Allowing dirt or liquid to enter into the electric device or connection box.

Using cables that can't withstand the maximum current values of the electric device.

Using dirty cable lugs or broken tools.

Connecting power cables so that there is less than 10 mm air gap between the cable lug andother metallic structure (including the braid of the cable).

Storing the electric device contrary to the guidelines presented in this user guide, forexample, outdoors in wet or dusty conditions.

Storing the electric device without proper support that prevents overturning and falling.

For product speci�c and up to date information see product data sheets, http://www.danfoss.com.

EC-LTS1200-410

3. Product overview


http://www.danfoss.com/

System introduction

Cooling

Table 4. Cooling system requirements

Cooling system properties Speci�cation

Cooling type Liquid cooling

Coolant type Water or water glycol mixture (glycol max. 50 %)

Coolant temperature -40º…+65 ºC

Coolant �ow minimum 10 l/min

Maximum operating pressure 2 bar

Pressure drop 40 mbar with 10 l/min (+25 °C coolant)

See detailed information and speci�cations from the product data sheets, www.danfoss.com.Rated values can be found from the rating plate.

Rating plate

Each electric device has a rating plate (also called product label) which can be found on top of theelectric device. The rating plate contains device rating and identi�cation details. Figure belowshows an example of a rating plate. The rating values in the Figure are illustrations only. For theexact information, see the rating plate on the electric device and product data sheets,http://www.danfoss.com.

Figure 3. Rating plate example

EC-LTS1200-410

3. Product overview


https://danfoss9247.dox.fi/www.danfoss.comhttp://www.danfoss.com/

Table 5. Rating plate �elds

Field Explanation Unit

1 Electric device product family

2 Electric device device full type code including possible options

Serial No. Serial number

n ph Number of phases

U nom Nominal voltage V

U range Voltage range V

f1 Frequency Hz

I nom Nominal current A

P nom Nominal power VA

Manuf. Manufacturing year

Duty Duty class

Cooling Cooling type

TC Coolant temperature °C

QC Coolant �ow l/min

IP class Enclosure class according to IEC60034-5

Mass Total weight of the electric device kg

Tamb Ambient temperature limits °C

Tstorage Storage temperature limits °C

Max. pressure Coolant maximum pressure bar

The rating plate and its values shown here may not all be relevant for every electric device.

Tightening torques

For correct and safe operation, it is essential to use speci�ed tightening torques for the electricdevice screws. Tightening torques (screw preloads) used in the electric device are shown in thetable below.

Tightening torque tolerances are: -10%...0% of the speci�ed tightening torque. Exceeding the speci�ed tightening

torque is not allowed.

EC-LTS1200-410

3. Product overview


Table 6. Tightening torques

Connection Torque

Electric device mounting screws, M8 20 Nm

Connection box lid (power terminal cover) mounting screws 4 Nm

Cable lug mounting screws 15 Nm

Grounding cable mounting screws, M8 20 Nm

Cable gland (tighten from the frame of the gland) 15 Nm

EC-LTS1200-410

3. Product overview


Because of the low weight of the electric machine, lifting can be done manually. If necessary, the mounting points can be

used for lifting with correct lifting eyes and lifting equipment.

Transportation

The electric device is shipped in �rst class condition. Products are inspected and packedcorrectly to prevent damage from ordinary handling during the transportation. Transportationconditions shall be in accordance with the product speci�cation, any kind of shocks must beavoided.

Plug and seal the cabling and cooling connections for transportation.

Receiving and unpacking

Inspect the electric device and the package immediately upon arrival. Ensure that the rating platedata in the cover letter complies with the purchase order. All external damage in the package or inthe electric device must be photographed and reported to Danfoss immediately.

Lifting

Use correct, adequately dimensioned lifting devices and inspect them before lifting.

Do not apply any excess weight on the electric device when lifting.

Use correct lifting slings. Use correct position and angle of lifting. The maximum permissible range of lifting angles is

shown in lifting �gures.

Make sure that lifting slings are correctly routed so that they do not cause momentum on any of the signal connectors.

See the rating plate and data sheets for weight information.

Lift the electric device using the correct lifting lugs/eyes only. See lifting �gures in this Chapter.

Do not go under a lifted load.

The weight of the electric device is under 25 kg, so lifting it by hand is possible in most cases. If it is necessary to lift the

electric device with a lifting device, install two lifting eyes in the threaded installation holes and lift from them. Obey the

local legislation and recommendations.

EC-LTS1200-410



Figure 4. Correct lifting and incorrect lifting

Horizontal lifting

Figure 5. Maximum permissible lifting angles

EC-LTS1200-410



Figure 6. Horizontal lifting

1. M8 lifting eye, DIN580.

Handling

When turning or lifting the electric device, lift it in the air in order to prevent damage to

the chassis or other parts of the electric device.

Although the electric device is designed to operate in harsh and demanding environment, anymisuse or improper handling of the electric device is prohibited to avoid malfunctions later.

EC-LTS1200-410



Storage

When the device is dismounted and stored and packed for delivery, measure that there is

no voltage and then install short circuit wire to the conductor rails to prevent charge

from building up.

Store the electric device always indoors having the storage temperature preferably above -20 ºCand the relative humidity less than 60 %. Storage conditions should be dry, dust free and vibrationfree.

Make sure that the cabling and cooling connections are plugged and sealed before storage.

The electric device must not be subjected to any external vibrations during storage to avoidpossible hidden structural damages.

EC-LTS1200-410



Required tools

Risk of electric shock during electrical installations. Use insulated tools.

Following tools are required to install the electric device:

Ratchet torque wrench.

Hex head wrench kit with different metric sizes.

Socket wrench kit with different metric sizes.

Cable gland tightening tool. Size according to cable glands.

Cable skinning knife.

Crimping tool for cable lugs.

For more detailed information, see appropriate chapters in this user guide and product datasheets, http://www.danfoss.com.

Mechanical installation

Allowed mounting position

Do not place the electric device on the ground without proper mounting or protective structure.

See an example in Figure Required customer mounting structure.

The electric device must be mounted on a �at, heat- and �ame-resistant mounting place (forexample on a bracket).

The electric device can be mounted in any direction. Mount the electric device permanentlyfrom the mounting points.

Mounting points are shown in the Figure below.

EC-LTS1200-410

5. Installation


http://www.danfoss.com/

Figure 7. Location of the mounting points

1. M8x1.25 (18 mm Deep ) 14 pcs (6 pcs on the sides, 8 pcs on the bottom)

To ful�ll the mechanical and environmental standards, for example vibration and shock, it

is recommended to mount the electric device from the bottom or from the side, with at

least 6 pcs of M8 screws.

Selected mounting position must allow the cooling system to work properly. Bleed the air awayfrom the cooling channels to prevent air pockets.

EC-LTS1200-410

5. Installation


Installation procedure

Risk of electric shock when the connection box lid is open. Make sure that the electric device is discharged; measure the

voltage to make sure of safety.

Heavy electric device. Handle with care. Handle the electric device correctly when you install it to the correct mounting

position. See chapter Handling for more information

Measure the insulation resistance of the electric device before and after the installation of the electric device.

When installing the connection box lid, make sure there are no foreign particles between the connection box lid and the

insulation and that all connection box fasteners are in place. Missing or loose screws can compromise the insulation.

Preparations

Make sure that the chosen installation place ful�lls the environmental requirements speci�edfor the electric device.

Protect the electric device against corrosive gases, liquids, conductive contaminants (such ascondensation, carbon dust, and metallic particles) and sprays or splashing water from alldirections.

Protect the electric device in high humidity, salty or chemical content environments withsuitable additional enclosure.

The mounting place and mounting interfaces should be sufficient to carry the weight of theelectric device.

Make sure that the electric device has sufficient mounting and operating clearances formaintenance work.

Installation procedure may vary from that shown in this user guide. All steps must be includedin the procedure, although the order of the steps can be different.

Installation procedure

1. Prepare the installation place and make sure that it meets the requirements for the product.

2. Lift and support the electrical device for the mounting. Refer to Chapter Lifting.

3. Install all appropriate mounting screws, do not tighten the screws until they are aligned andpre-installed. See the tightening torques from Chapter Tightening torques.

4. Connect the cooling system. See chapter Cooling connections or the Main dimension drawingfor connection details. Make sure that there are no air pockets in the cooling channels and that thecoolant goes freely in and out. Make sure that the cooling system operates correctly.

5. Make sure that the devices and machines you will connect to the electric device have novoltage.

6. Make the grounding of the frame of the electric device by direct contact between it and themetal bracket and / or from the protective earth contacts. The grounding contacts must be paint-free. See Chapter Grounding.

EC-LTS1200-410

5. Installation


Cooling connections

Make sure that cooling liquid runs freely in and out from the electric device.

When selecting cooling liquid nipples, choose nipples that can resist galvanic corrosion.

To prevent damage to the cooling connectors, refer to the documentation of the manufacturer for the correct tightening

torque of the cooling liquid nipples.

Connect the electric device directly to the cooling circuit.

Make sure that the coolant �ow is equal or higher than rated and the coolant temperature atthe inlet of the electric device is lower or equal to the rated temperature.

For more information, see Chapter Recommended coolants and product data sheets. Ratedvalues can be found on the rating plate of the electric device.

It is recommended to �x the hose on the coolant connection with a hose clamp or a hose clipafter the protection cap has been removed.

Use water/glycol mix or pure water with corrosion inhibitor as the coolant.

Recommended coolants

Ethylene glycol is a toxic compound. Avoid exposure to the coolant. Handle with care. Use appropriate personal

protective equipment when you handle the coolant.

The electric device works correctly with water based coolant. Plain water with appropriatecorrosive inhibitor is acceptable, for example water with maximum of 50% glycol coolant. Ethylene

glycol based Glysantin® G48® (includes also corrosion inhibitors) or similar can be used. Propylene

glycol based coolants, like Splash® RV&Marine antifreeze, can also be used. Propylene glycol isrelatively safe compound for humans and the environment.

EC-LTS1200-410

5. Installation


Electrical installation

Before you start the electrical installation make sure that the frame of the electric device is grounded correctly. Refer to

Chapter Grounding.

Risk of electric shock when power terminal cover is open. When working with the power connections make sure that

electricity has been disconnected and the electric device has discharged.

Cable lugs are not included in the delivery.

Refer to wiring diagram for details about electrical wiring.

Grounding

Make sure that the electric device is correctly grounded. Do not operate the electric device without correctly attached

protective earth conductor. Obey the installation instructions and the guidelines for component selection given in

this user guide.

The grounding cable must be able to carry the maximum supply fault current which normally will be limited by the fuses

or the Miniature Circuit Breaker (MCB). Put correctly rated fuses or MCB in the mains supply of the electrical device: obey

the local legislation and recommendations.

Obey the installation instructions and the guidelines for component selection given in this user guide.

Make sure that the safety grounding is correct. Refer to Chapter Mechanical installation.

Generic grounding guidelines

Connect the ground terminal of each electric device individually to the site grounding bus bar(through the �lter if installed).

The grounding connections cannot loop from one electric device to another electric device, orto any other piece of equipment, or from any other piece of equipment.

Ground impedance must be compliant with local industrial safety regulations.

The protective ground of the unit must be connected to the system ground. Groundimpedance must meet with the requirements of national and local industrial safety regulationsand electrical requirements. The condition of the grounding connections must be checkedperiodically.

Make sure that all grounding surfaces are clean and remove paint from the contact areas.

For detailed information, see appropriate chapters in this user guide.

Main frame

EC-LTS1200-410

5. Installation


The best grounding is achieved when the main frame of each electric device is directly connectedto the ground. If this is not possible, the electric device must be grounded at least from one of thesafety grounding points with an appropriate grounding cable. For good functional grounding usewide �at grounding braid. Round grounding wires are adequate for safety grounding but itdoes not provide very good functional grounding because of its higher impedance at highfrequencies. The grounding points are marked to the electric device.

There are two marked safety grounding points, however, any of the mounting points can be usedfor grounding.

Figure 8. Grounding points

1. Grounding connection: M8 hole. Refer to Main dimension drawing if necessary.

Safety grounding points and protective earth conductor

Touch current in the protective earth conductor exceeds 3,5 mA AC and 10 mA DC.

The cross sectional area of the protective earth conductor must be at least equal to that of the incoming supply

conductor.

One of the safety grounding points must be connected to adjacent building steel (girder, joist), a�oor ground rod, or bus bar. Grounding points must comply with national and local industrialsafety regulations and/or electrical codes.

Cabling and wiring

To make sure that the electric device functions correctly and to minimize the radiated emissions,all connected cables and wires must be EMC-shielded. Shieldings must be connected to theground at both ends of the cable or wire. All power connections must be secured with cable lugsand cable glands. EMC-shielded cable glands are used in all Danfoss products for the powerconnections. Make sure that the low voltage cable (control signal cable) shield is also groundedfrom the both ends.

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5. Installation


Cable gland assembly and power line connection

Risk of electric shock when the connection box lid is not installed.

When you work with the power connections make sure that electricity has been disconnected and the electric device has

discharged. Measure the level of the remaining voltage before you touch the power terminals.

All electrical connections must be done according to instructions. It is essential to make sure thatall terminal connections are installed properly and the and the intended application is suitable forthe product in terms of electrical requirements/characteristics.

The high current and high voltage cable harness for AC and DC connections needs to beterminated with cable lugs and cable glands. It is recommended to use IP67/68 rated, 360ºshielded cable glands and single core automotive rated screened cable. The cross section area of

the copper cable must be 70 mm2 or smaller, depending on the needed maximum current.

The cable gland has three functions, it works as a stress relief, it seals the connection against waterand dirt and provides appropriate EMI shielding. Advanced cable glands could achieve high EMIattenuation over a wide frequency range.

The cable lug and cable gland must be assembled according to instructions. For correct assemblyof the cable gland, it is recommended to use a torque key with a turnkey head and a key to adaptthe cable gland. The cable lug is connected to terminal with a M8 screw. Shielding of the powercable must be connected to the electric device body by the cable gland. Recommendations for thetightening torques must be followed.

Figure 9. Cable harness connection with the cable lug and the cable gland (for illustration only)

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5. Installation


The information below describes how to assemble screened power cables to the electric device.P�itsch BlueGlobe-series cable glands and H+S Radox Elastomer S automotive cables arerecommended. Cable gland assembly instruction can also be found from P�itsch gland catalogueavailable from http://www.p�itsch.de.

Cable lug and cable gland assembly steps

1. Remove the small hexagonal piece from the BlueGlobe-sealing insert as shown in Figure below.

Figure 10. BlueGlobe-sealing

2. Cut the cable sheath at the distance A from the end of the cable, see Figure below. Pull the cutpart of the sheath partly (length B is from 10 to 15 mm) off the cable as shown in the �gure.Distance A depends of the lenght of the used cable lug. Measure with the cable lug that is usedand cut to suitable lenght.

Do not remove the cable sheath completely at this point and do not cut the braid screen of the cable.

Figure 11. Cut lenght of the cable sheath

3. Insert the cable to the cable gland with slight turning motion. This helps the cable go throughthe spring inside the cable gland. Push the cable gland against the sheath of the cable as shown inFigure below.

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5. Installation


http://www.pflitsch.de/

Figure 12. Cable to the gland assembly

4. After the cable gland is in place remove the length A piece of the sheath and cut the braidscreen (cover) from 10 mm (distance C) from the gland bottom as shown in Figure below.

Make sure that the cable gland spring is against the cable sheath before cutting the braid screen

Figure 13. Cut the braid screen

5. Cut a piece of length D of the inner sheath shown in Figure below. The length D must be equalto the length of the cable lug body.

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5. Installation


Figure 14. Cutting the inner sheath

6. Place the cable inside the cable lug body, and crimp the cable lug twice in different places. SeeFigure below.

Figure 15. Connecting cable lug

7. Cut piece of shrink tube and shrink it over the cable lug and braid screen as shown in Figurebelow. This is done to keep the braid screen in place and for extra insulation.

The shrink tube must be speci�ed for operating temperature range from -40 ºC to 150 ºC. Self gluing shrink tube is

recommended.

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5. Installation


Figure 16. Shrink tube

8. Insert the cable through the corresponding hole in the electric device frame and connect thecable lug to the power terminal with the correct screw. Use spring washer between the cable lugand the connection screw or nut. Do not tighten the cable lug screw at this point to ensure �ttingof the cable gland.

Make sure that there is at least 10 mm air gap in between the cable lug and other metallic structures including the braid

of the cable. If the air gap is smaller, use extra insulation shrink tube to cover the lug.

9. Screw the cable gland to the power terminals of the electric device according to instructions.Tighten the cable gland with the speci�ed torque.

Tighten the gable gland from the gable gland body to enclosure with torque 15 Nm. Then tighten the cap of the gable

gland according to the instructions provided by gable gland manufacturer (recommendation P�itsch).

10. Tighten the cable lug using the speci�ed torque.

11. Repeat the procedure to the other cables and connections.

12. Close the power terminal cover and install the connector shield.

13. Make sure that the power cable shields are grounded properly.

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5. Installation


Figure 17. Cable lug and cable gland assembly cross- section

Table 7. Example of the equipment needed for the assembly

Description Manufacturer's homepage Art.No./Part No.

Assembly equipment (example)Torque key and turnkey head http://www.p�itsch.de 730N/10-50

Key http://www.p�itsch.de SE30

Assembly example for a 50 mm2

cable

Cable with nominal cross-section of 50

mm2http://www.hubersuhner.com Radox Elastomer S

Cable lug http://www.druseidt.de 10853

Cable gland http://www.p�itsch.deP�itsch blueglobe TRI bg

225ms tri

Screw http://www.wuerth.com DIN 912 M8x16 (item: 10285)

Washer http://www.wuerth.comDIN 2093, 8,2 x 16 x 0,9 (item:

17332)

Washer http://www.wuerth.com DIN 125 D8 (item: 10285)

Cabling and wiring

Route the power cables as far from the control signal wires as possible. The minimum separating distance is 100 mm. The

crossings must be in an angle of 90º. Power cables and control wires should be routed near the frame of the application.

Make sure that all terminal connections are tightened correctly.

Install the electric device by the instructions. Make sure that all the applications of the system, forexample, batteries are connected to the electric device by the instructions of this user guide andthe product speci�c guidelines.

Cabling

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5. Installation


http://www.pflitsch.de/http://www.pflitsch.de/http://www.hubersuhner.com/http://www.druseidt.de/http://www.pflitsch.de/http://www.wuerth.com/http://www.wuerth.com/http://www.wuerth.com/

For the power cables, it is recommended to use Radox Elastomer S, screened automotive cableor equivalent cable with similar speci�cations.

Use only EMI-shielded power cables to make sure the correct operation of the electric deviceand to minimize the radiated emissions. Cable shields must be connected to the electric deviceground at both ends of the cable. All Danfoss products use EMI-shielded cable glands forpower connections.

Wiring

To make sure of correct and steady operation, use EMI-shielded cables for the control signals of theelectric device. Cable shields must be connected to the electric device ground at both ends of thecable.

Table 8. Recommendations for control signal cables

Cable Cable type and properties

External temperature measurement (PT100/PT1000) shielded cable (twisted pair)

High voltage connections

The high voltage connections have a common ground connector.

UHV ≥ ULV

Make sure the power cables exit straight from the terminals and do not rub against the sharp cable through-holes or

other sharp edges which could wear out the cable insulation over time.

Do not place any excess weight on the connection box lid(s).

The electric device must be installed and connected according to the instructions.

Make sure that all the connected applications are connected to the electric device according tothe product speci�c operating voltage.

The electric device is delivered with the power terminal cover mounted. To access the powerconnections, remove the mechanical safety feature and the connection box lid.

For more information, see appropriate chapters in this user guide and the product data sheets.

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5. Installation


Low voltage connections

See the correct signal connections and product speci�c pin-layout from product data sheets, http://www.danfoss.com.

Table 9. Control signal connector information

Description Part number Supplier example

X2 temperature measurement connector M16 male 7.840.200.000

www.hummel.com

Insert 10-poleinsert: 7.003.910.101

Pin: 7.010.981.001

Mating connector M16 female 7.810.400.000

Insert 10-pole, M16, RCPT 7.003.910.102

Sensor Connector Socket 7.010.981.002

Figure 18. M16 connector

Table 10. Pin con�guration of temperature measurements (M16 connector, one sensor perinductor)

PIN Description

1 Temperature 1, PT100 (P), inductor

2 Temperature 1, PT100 (N), inductor





7 Enclosure ground (shield)

8 Reserve

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5. Installation


http://www.danfoss.com/enhttps://danfoss9247.dox.fi/www.hummel.com

Operation conditions

The electric device should be used for its intended purpose only and within limits speci�ed by themanufacturer, concerning:

Loading.

Cooling.

Service interval.

Ambient conditions such as temperature and moisture.

The electric device is designed for these conditions:

Maximum altitude 4000 m above sea level.

If the operation limits are exceeded and the electric device is damaged, please contact localDanfoss representative.

Condition monitoring during operation

Risk of permanent damage to the electric device. Use the electric device only in the ambient conditions given in this user

guide and in the data sheet.

Risk of permanent damage to the electric device. Use the electric device only if the technical guidelines given in this user

guide and in the data sheet are met.

Risk of permanent damage to the electric device. If you notice deviations from the normal operation (for example: high

temperatures or noise), stop the electric device. Find the reason for the deviation and take action to repair the

functionality of the electric device. Refer to Chapter Troubleshooting for more information.

Temperature trip on the electric device is 155°C. Connect the three PT-100 temperature sensors to the converter.

Monitor the electric device regularly during operation to make sure of reliable operation, toforesee possible upcoming failures and to help to reach the designed lifetime of the product.

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6. Operation


Do not disassemble the electric device. You can do only procedures described in this user guide. For further

information contact Danfoss representative.

Only trained and quali�ed personnel that are familiar with the relevant safety requirements can do any maintenance

to the electric device.

Risk of electric shock when the connection box lid is removed.

Use correct personal protective equipment when you operate near the electric device.

Read the instructions in the user guide before you install the electric device. To make sure of safe and reliable

operation of the electric device, obey the maintenance instructions.

Cooling system maintenance

The cooling system of the electric device requires regular observation and maintenanceactivities. Observe weekly that the cooling system operates correctly and check monthly that thereare no leakages in the cooling system. The quality of the coolant must be checked yearly. Themixture of water and glycol as well as the type of the glycol used must be as speci�ed. SeeChapter Recommended coolants.

Regular maintenance

Inspect the electric device at regular intervals. Use the regular maintenance checklists in the inspections.

Do not attempt to tighten or release any screws, nuts or joints which are not shown in this user guide and that are not

involved in the normal installation and maintenance procedures.

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7. Maintenance


Table 11. Maintenance intervals

Object Check/Task Weekly Monthly Yearly

General

construction

OperationAbnormal phenomenon, for example noise or heating. If clearly increased,

contact Danfoss representative.X

MountingTightness of the screws. Tighten to proper value if necessary. Applies to screws

that are presented in this user guide. See chapter Tightening torques.X

Enclosure and

connected partsCheck cleanliness. Clean if necessary. See chapter Cleaning. X

Electrical

system

Cables Visual check, for example wear. Replace if necessary. X

Electrical

connections

Check connections. Ensure that sufficient tightening torque is applied to cable

glands. See chapter Tightening torques.X

Groundings

(earthings)

Check groundings (earthings). Ensure that the connection resistance is valid.

Re-connect if necessary.X

Cooling

system

Operation Functioning. Cooling system functions as speci�ed. X

Ventilation plug Cleanliness. Clean if necessary. See chapter Cleaning. X

Cleaning

Do not use pressure washer for cleaning. High water pressure may damage the gaskets allowing water to go in to the

electric device.

Risk of electric shock if the electric device is cleaned against instructions allowing water to go in to the electric device.

Keep the electric device clean. For cleaning, use non-abrasive and non-corrosive cleaningproducts. Make sure that the detergent can be used for aluminum.

When cleaning the air vents, do not open / remove the vents. Clean the vents from the outside.

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7. Maintenance


Risk of electric shock if dismounting steps are continued before the electric device is discharged and a safe voltage level

has been measured.

Do not touch the electric device or continue to work with the electric device until it cools down.

Support the electric device during dismounting, handle it with care.

Refer to the Chapter Installation for additional information.

Dismounting procedure

1. Switch off the electric device.

2. Make sure that the cooling system remains operational.

3. Always measure that no voltage is present on the power terminals before you proceed.

4. Wait until the temperature of the electric device and cooling liquid has decreased below +40 °C.

5. Remove the mounting screws and dismount the electric device from the mounting base.

6. Disconnect the power terminal cabling.

7. Disconnect grounding cables (protective earth).

8. Disconnect the liquid cooling system.

9. Remove the mounting screws and dismount the electric device from the mounting base.

10. Install the connection box lid and other parts and plug all electrical and cooling connectionsfor longer storage.

11. Lift the electric device off.

Disposal of the electric device

Dispose of the electric device and any of its parts by local laws and regulations.

EC-LTS1200-410

8. Dismounting and disposal of the electric device


Do not activate the automatic fault reset function on any system where it can be the cause of a potentially dangerous

situation.

Do not try to repair the electric device. In the case of suspected fault or malfunction, contact Danfoss or authorized

service centre for further assistance.

For the reason of general safety and correct operative actions, read the instructions carefully before you start any

analyses or work with the electric device.

Use correct personal protective equipment when you are near the electric device.

Some unexpected situations may occur while operating the electric device. Some of the possiblecauses and actions are given in table below. If an unexpected situation occurs, it should becorrected as soon as possible.

These instructions do not cover all details or variations in the equipment nor provide informationfor every possible condition to be met in connection with installation, operation or maintenance.

Table 12. Troubleshooting

Fault description Possible cause Action

Electric device overheating

Cooling system failure.

Inspect the cooling system operation and functionality,

especially possible leaks, �ow rate and �uid temperature.

Change the cooling �ow direction to �ush the cooling system

from sediment possibly accumulated.

Leakage in the cooling system. Inspect the cooling system circuit and connections.

Rigid particle inside the cooling

channel of the electric device.

Try to pulsate coolant to open the channels.

Contact Danfoss representative.

Signi�cant coolant leak

Loose connection in the cooling system.

Inspect, clean and tighten the connections. Replace them if

neccessary.

Broken cooling hose. Replace the cooling hose.

Electric device does not work

correctly or the performance is poor

Poor powerline contacts (high voltage)

Inspect, clean and tighten the contacts.

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Service policy

Maintenance and service of the electric device is limited to the procedures described in this userguide. See Chapter Service parts below for available service and accessory parts. For furtherinformation, contact Danfoss representative.

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Service parts

The recommended service parts are listed in the Table below. Contact Danfoss representative formore information and purchasing.

Figure 19. Service parts

Table 13. Service parts

Position Item / order number Quantity Description

1 35409 1 LID WITH EXTRUDED GASKET

2 10348 3 M25 x 1,5 BG PFLITSCH, BG225MSTRI

3 10473 3 M32 x 1,5 BG PFLITSCH, BG232MSTRI

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Table of Contents1. General information1.1. Copyright1.2. Intended use of the user guide1.3. Product naming convention1.4. Conformity according to standards1.5. Warranty1.6. Terms and abbreviations1.7. Trademarks1.8. Responsibility of the manufacturer

2. Safety information2.1. General safety statement2.2. Safety message signal words2.3. Safety symbols2.4. Personal protective equipment2.5. Electromagnetic compatibility (EMC)2.6. Installation safety2.7. Operation safety

3. Product overview3.1. Intended use of the electric device3.2. System introduction3.3. Cooling3.4. Rating plate3.5. Tightening torques

4. Transportation and storage4.1. Transportation4.2. Receiving and unpacking4.3. Lifting4.4. Handling4.5. Storage

5. Installation5.1. Required tools5.2. Mechanical installation5.2.1. Allowed mounting position5.2.2. Installation procedure5.2.3. Cooling connections5.2.4. Recommended coolants

5.3. Electrical installation5.3.1. Grounding5.3.2. Cable gland assembly and power line connection5.3.3. Cabling and wiring5.3.4. High voltage connections5.3.5. Low voltage connections

6. Operation6.1. Operation conditions6.2. Condition monitoring during operation

7. Maintenance7.1. Cooling system maintenance7.2. Regular maintenance7.3. Cleaning

8. Dismounting and disposal of the electric device9. Troubleshooting10. Aftersales10.1. Service policy10.2. Service parts

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